Faurecia Seating FEA Strategy

Transcription

1 9. LS-DYNA Forum, Bamberg 2010 Keynote-Vorträge II Faurecia Seating FEA Strategy C. Lemaitre Faurecia Sièges d Automobile 2010 Copyright by DYNAmore GmbH A - II - 1

2 Faurecia Automotive Seating FEA Strategy Christophe LEMAITRE Validation Director 9th German LS-DYNA forum th-13th 13th October 2010, Bamberg, Germany

3 2

4 3

5 Challenging CAE topics on a key automotive product! 4

6 Our game field Regulations : ECE 14 / ECE 17 / FMVSS210 / FMVSS201 / Low speed FMVSS202a / Safety : Front crash / Rear crash / Luggage impact / Low speed Whiplash / Functional : Static & Dynamic comfort / Mechanical resistance / Misuse / Climate ageing / Cycling / Vibration ageing / Squeak & Rattles / Red = simulable by FEA Different materials behaviors : Steels / Foams / Plastics Different modeling scales : seat frame / seat mechanisms Integration of restraint systems Integration of dummies 5

7 Main OEMs expectations Cheaper products : More Product & Process design optimizations Lower engineering costs (CAD, prototypes, testings ) Shorter development time Lighter parts DESIGN More product requirements : Regulations Occupants safety (Ncap) Comfort Perceived quality HOW? TESTING FEA More quality / robustness : Less PPM Low product sensibility to Design & Manufacturing parameters More product durability with time Higher reactivity / adaptability towards market : More product versions More changes on styling / specifications / functions during development 6

8 Our 5 Validation Fundamentals (VALIDATION = FEA + TEST) Focus FEA/Test pilots on results analysis & product design High integration and involvement of FEA/Test pilots into R&D projects Use Innovative + Robust + Lean FEA/Test standards High interaction between FEA and TESTING Use FEA as an upfront design tool (CAE CAD) 7

9 From our 5 Validation Fundamentals to our Validation roadmap FEA/Test Pilots organization Validation on projects Pilots skills Validation development tools Project KPIs Lab operations FEA operations Labs Labs FEA OEMs FEA equipments quality system equipments certifications Standard test methods OEMs lab certifications Advanced FEA T&M FEA LCC Measurements uncertainties Lean testing FEA quality system 8

10 From our 5 Validation Fundamentals to our Validation roadmap FEA/Test Pilots organization Validation on projects Pilots skills Validation development tools Project KPIs Lab operations FEA operations Labs Labs FEA OEMs FEA equipments quality system equipments certifications Standard test methods OEMs lab certifications Advanced FEA T&M FEA LCC Measurements uncertainties Lean testing FEA quality system 9

11 FEA and TEST people integration on R&D projects Previous organization Program Manager Program Manufacturing Leader Program Buyer Program Sales Leader Program Development Leader w/ Design leaders and CAD Program Quality Leader Program Controller FEA Eng Test Eng LCC FEA Test labs Working modes: FEA Eng = FEA results provider Test Eng = Test results provider LCC FEA = meshing/models provider FEA/Test managed by 1 non expert leader Consequences : Low motivation of FEA/Test Eng in project FEA used as validation tool more CAD cost High risk of bad FEA/Test correlations Low FEA/Test interaction no cost optimization 10

12 Organizational chart FAS R&D / Validation Department Central Services FEA Methods & Tools Testing Methods & Equipments Quality & Lean STRATEGY & STANDARDS DELIVER INNOVATIVE + ROBUST + LEAN FEA and TEST STANDARDS 11

13 Organizational chart FAS R&D / Validation Department Central Services FEA Methods & Tools Testing Methods & Equipments Quality & Lean Validation France Cust. Validation FEA & Test Pilots Brières Validation Germany Cust. Validation FEA Pilots FEA Poland FEA Engineers Validation Brazil FEA & Test Pilots Test Operations Validation USA FEA Pilots Test Pilots Validation China FEA & Test Pilots FEA Engineers Test Operations Shanghai FEA & Test Pilots Flers Test Pilots Test Operations Test Operations Wuxi Test Operations Brières/Sel. Test Operations STRATEGY & Test Operations Flers OPERATIONS STANDARDS APPLICATION OF FEA and TEST STANDARDS ON PROJECTS FEA + TEST PEOPLE IN 1 DEPARTMENT 1 UNIQUE MANAGER 12

14 Organizational chart FAS R&D / Validation Department Central Services FEA Methods & Tools Testing Methods & Equipments Quality & Lean Validation France Cust. Validation FEA & Test Pilots Brières Validation Germany Cust. Validation FEA Pilots FEA Poland FEA Engineers Validation Brazil FEA & Test Pilots Test Operations Validation USA FEA Pilots Test Pilots Validation China FEA & Test Pilots FEA Engineers Test Operations Shanghai FEA & Test Pilots Flers Test Pilots Test Operations Test Operations Wuxi Test Operations Brières/Sel. Test Operations STRATEGY & Test Operations Flers OPERATIONS STANDARDS FEA PILOTS + TEST PILOTS in 1 DEPARTMENT 1 UNIQUE DIRECT MANAGER 13

15 Pilots integration on R&D projects Current organization Program Manager Program Manufacturing Leader Program Buyer Program Sales Leader Program Development Leader w/ Design leaders and CAD Program Quality Leader Program Controller FEA Pilot Test Pilot LCC FEA Test labs Working modes: FEA Pilot = Design by FEA engineer Test Pilot = Design by Test engineer LCC FEA = FEA Calculations & Analysis provider FEA/TEST managed by 2 expert engineers Consequences : High motivation of FEA/Test Pilots in project FEA used as design tool less CAD cost Low risk of bad FEA/Test correlations High FEA/Test interaction cost optimization 14

16 Pilots integration on R&D projects Best organization Program Manager Program Manufacturing Leader Program Buyer Program Sales Leader Program Development Leader w/ Design leaders and CAD Program Quality Leader Program Controller Validation Pilot LCC CAE Test labs Working modes: Validation Pilot = Design by FEA/Test engineer LCC FEA = FEA Analysis & Design solutions provider FEA/TEST managed by 1 expert engineer Consequences : High motivation of FEA/Test Pilots in project FEA used as design tool less CAD cost No risk of bad FEA/Test correlations Automatic FEA/Test interaction cost optimization 15

17 FEA LCC What the FEA HCC think about FEA LCC? Need long or powerpoint to explain my FEA request Don t understand my FEA request Pure FEA provider, no support on my design issues Not reactive, quicker if done by myself Their FEA skill is too weak, why should I train them? Quality is low FEA PILOT (HCC) THEY ARE TAKING MY JOB! 16

18 FEA LCC What the FEA LCC think about FEA HCC? Always pressing me by giving short deadlines Not able to formalize a clear FEA request Need long or powerpoint to ask details on FEA request Don t want to give me more data on the project Give me only basic FEA operations : no results analysis, no design proposal Think I am not as skilled in FEA as him FEA LCC Engineer (HCC) WHY SHOULD I BE MORE PROACTIVE OR MOTIVATED? 17

19 LCC FEA HCC/LCC FEA new organization 1 Validation Pilot (HCC) STANDARD FEA TOOLS & METHODS 1 standard for FEA hardware & softwares 1 FEA quality system w/ internal audits 1 worldwide FEA database (dummies, raw materials, weldings, screws ) 1 efficient shared desktop tool 1 library of FEA training modules Dedicated FEA Engineers (LCC) (Calculations / Analysis / Design) FEA Pool (LCC) (Meshing / Model preparation) PILOT MISSION : By using FEA & Testing, to design a robust product compliant with all requirements (specifications, regulations, weight, cost, ) To minimize the prototyping and testing costs. PILOT FOCUS : FEA and test results analysis Find design solutions by relaunching FEA or testing Communication w/ project team and customer CONSEQUENCES for PILOT : Need to outsource more key FEA tasks to LCC Need to get full involvement in his project Need to get full proactivity on design Permanent communication (goals, issues, decisions, OEM feedback ) is KEY SUCCESS FACTOR 18

20 LCC FEA HCC/LCC FEA new organization RESULT = WIN / WIN between FEA HCC and LCC engineers Significant increase of key competencies : Pilots : product design, project management, leadership, communication, negotiation, customer relations management FEA LCC engineers : FEA analysis, product design, Higher project involvement and design proactivity Less resignations and people turnover in LCC Increase of LCC FEA on HCC projects X m dev. cost saving! HCC pilots satisfaction on LCC FEA LCC engineers : 57% meet expectations + 25% above expectations = 82% positive expectations 19

21 From our 5 Validation Fundamentals to our Validation roadmap FEA/Test Pilots organization Validation on projects Pilots skills Validation development tools Project KPIs Lab operations FEA operations Labs Labs FEA OEMs FEA equipments quality system equipments certifications Standard test methods OEMs lab certifications Advanced FEA T&M FEA LCC Measurements uncertainties Lean testing FEA quality system 20

22 Pilots skills development Targets : to help integration of new people to assess and manage skills to help present people mobility to standardize and improve skills of present people to capture / structure / redeploy knowledge + know how + best practices Specific trainings modules : FEA operations Product performances Testing operations Validation leading Product & Process design Soft skills 21

23 Pilots skills development 22

24 Pilots skills development 23

25 Pilots skills development Key document = FEA Pilot & Test Pilot job guidelines : To help pilots to run their job To help integration and training of new pilots To improve rigor and discipline in work execution To standardize validation actions & deliverables on all projects To increase robustness of our products development To help projects follow up and review by management 24

26 Pilots skills development Secure FEA set up vs TEST set up Secure parts definition before testing Secure MFG process effects integration Secure product robustness / DOE approach 25

27 From our 5 Validation Fundamentals to our Validation roadmap FEA/Test Pilots organization Validation on projects Pilots skills Validation development tools Project KPIs Lab operations FEA operations Labs Labs FEA OEMs FEA equipments quality system equipments certifications Standard test methods OEMs lab certifications Advanced FEA T&M FEA LCC Measurements uncertainties Lean testing FEA quality system 26

28 FEA softwares strategy 2008 status RADIOSS PAM CRASH LS DYNA How to deliver the same FEA quality for all customers on all projects? How to reduce cost to get best FEA quality? 27

29 FEA softwares strategy 2008 status Consequences for faurecia : Significant cost to maintain competencies on all softwares Difficulties to manage differences in FEA results because softwares FEA pilots spend more time in FEA issues than design products No standardization FEA tools & methods & databases No optimization of softwares licenses costs Difficulties to capitalize correlations and best/bad practices High cost to develop and deploy new advanced FEA Inefficiencies to share and exchange FEA models between products High cost to integrate new collaborators High training cost Less headcount flexibility between projects and sites Consequences for customers : Able to integrate directly faurecia FEA models But not the best FEA models from faurecia 28

30 FEA softwares strategy Since WORLDWIDE STANDARD FEA SYSTEM HYPERMESH LS DYNA HYPERVIEW FAURECIA FEA SOFTWARES TRAINING MODULES FEA QUALITY SYSTEM DATABASES Key benefits : Same FEA Quality for all customers on all projects Huge possibilities for standardization / knowledge capitalization / FEA improvements Costs reductions : Training : -60% Licences : -33% 29

31 FEA softwares strategy Since 2009 Dummies Database Belts models Body blocks Material Database Screws Database Mechanisms Database Efficiency Tools Stadthagen Grojec Troy Flers Brieres Shanghai Pune Master database Quattro Barras Automatically replicated databases Same FEA IT environment (hardware / softwares / databases / models) 30

32 FEA softwares strategy Interface w/ customers TRANSPARENCY and TRUST Faurecia : Uses its FEA system and is responsible of its results Is responsible to design a seat compliant w/ specifications Delivers FEA models compliant w/ customer key project milestones Provides support for models conversion But can not be responsible of differences in FEA results between softwares Organizes regular exchanges w/ customers to share FEA best practices Develops a policy of OEM FEA certifications 31

33 FEA softwares strategy FEA OEM certifications Process = AUDIT + BLIND TEST STEP 1 faurecia FEA system audit STEP 2 FEA results Loadcase 1 FEA results Loadcase 2 FEA results Loadcase N STEP 3 Compare FEA / test results Loadcase 1 Compare FEA / test results Loadcase 2 Compare FEA / test results Loadcase N Certification Loadcase 1 Certification Loadcase 2 Certification Loadcase N Faurecia task Customer task 32

34 FEA softwares strategy FEA OEM certifications Faurecia benefits : Strong competence recognition Reduce sterile discussions about FEA results robustness More responsibilities on FEA results OEM benefits: Deep knowledge of faurecia FEA robustnesss Sort suppliers on FEA robustness Reduce FEA cost by not remaking FEA already done faurecia 33

35 From our 5 Validation Fundamentals to our Validation roadmap FEA/Test Pilots organization Validation on projects Pilots skills Validation development tools Project KPIs Lab operations FEA operations Labs Labs FEA OEMs FEA equipments quality system equipments certifications Standard test methods OEMs lab certifications Advanced FEA T&M FEA LCC Measurements uncertainties Lean testing FEA quality system 34

36 Standard test methods Objectives : To standardize execution of testing between labs Same reading and understanding of OEMs specifications & regulations Same test set up and measurements set up Same testing execution Same quality of testing deliveries Same best practices To reduce test results variability & uncertainty To help people learning and integration To improve test methods by capitalizing knowledge & experiences Standardization process = TEAM WORK Testing experts FEA Tools & Methods team Product performances experts 35

37 Standard test methods Test method content : Faurecia test method = default method : Recommended equipments Test preparation and set up Measurements preparation and set up Checklists before, during, after testing Specificities by OEM 3 quality levels : Test for FEA correlation Application test COP test Technical internal audits to control application standard test methods Standard test methods Available Front crash Rear crash Whiplash & FMVSS208 ECE 14 & FMVSS210 HRMD Squeak & Rattles ECE 17 backrest ECE 17 headrest ECE 17 luggage Luggage crash Maximum recliner torque 45/15 Acoustic measurements Vibration durability Modal analysis Egress/Ingress 36

38 FEA Quality System 1 Worldwide FEA quality system Objectives : To facilitate people learning & integration To standardize FEA know how / processes / best practices To reduce results variability induced by FEA people To secure quality of FEA deliveries and design decisions To improve correlations between FEA & Test results To improve FEA quality by capitalizing knowledge & experiences Tools : Documents : FEA guidelines Standard FEA method Technical internal audits to control application of FEA quality system 37

39 FEA Quality System FEA Quality docs : Available Guidelines LS Dyna core guidelines FEA audit process FEA LCC outsourcing process FEA report Correlation process DOE process FEA method Front crash & Rear crash Whiplash & FMVSS208 ECE 14 & FMVSS210 H point and HRMD ECE 17 backrest ECE 17 headrest Static comfort and pressure mapping Standard FEA method prerequisite = Standard Test method! 38

40 FEA quality sytem + Standard test methods 1 QUALITY SYSTEM SAME FEA/TEST RESULTS BETWEEN R&D CENTERS 39

41 Conclusions Mindset change of R&D people Huge steps towards FEA & Testing standardization Same FEA / Test results and services between R&D centers Very positive feedback from project teams and customers Our original approach needs talented people join faurecia! Significant testing costs reduction for evidences join 8th European LS- DYNA Users Conference, 23 rd -24 th May 2011, Strasbourg, France 40

42 THANK YOU FOR YOUR LISTENING! 41

43